SIST EN 1804-1:2002

SLOVENSKI STANDARD
SIST EN 1804-1:2002
01-junij-2002
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Machines for underground mines - Safety requirements for hydraulic powered roof
supports - Part 1: Support units and general requirements
Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen für hydraulischen
Schreitausbau - Teil 1: Ausbaugestelle und allgemeine Anforderungen
Machines pour mines souterraines - Exigences de sécurité relatives aux soutenements
marchants applicables aux piles - Partie 1: Unités de soutenement et exigences
générales
Ta slovenski standard je istoveten z: EN 1804-1:2001
ICS:
73.100.10 Oprema za gradnjo predorov Tunnelling and tubbing
in podzemnih železnic equipment
SIST EN 1804-1:2002 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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EUROPEAN STANDARD
EN 1804-1
NORME EUROPÉENNE
EUROPÄISCHE NORM
October 2001
ICS 73.100.10
English version
Machines for underground mines - Safety requirements for
hydraulic powered roof supports - Part 1: Support units and
general requirements
Machines pour mines souterraines - Exigences de sécurité Maschinen für den Bergbau unter Tage -
relatives aux soutènements marchants applicables aux Sicherheitsanforderungen für hydraulischen Schreitausbau
piles - Partie 1: Unités de soutènement et exigences - Teil 1: Ausbaugestelle und allgemeine Anforderungen
générales
This European Standard was approved by CEN on 21 September 2001.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2001 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 1804-1:2001 E
worldwide for CEN national Members.

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EN 1804-1:2001 (E)
Contents
page
Foreword. 3
0 Introduction. 3
1 Scope . 3
2 Normative references . 4
3 Terms and definitions . 5
4 List of hazards . 7
5 Safety requirements . 7
6 Verification of the safety requirements . 11
7 User information . 12
Annex A (normative) Tests for verification of the safety requirements and calculation. 17
Annex ZA (informative) Relationship of this document with EC Directives . 33
Bibliography . 34
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EN 1804-1:2001 (E)
Foreword
This European Standard has been prepared by Technical Committee CEN/TC 196 "Machines for
underground mining - Safety", the secretariat of which is held by BSI.
This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by April 2002, and conflicting national standards shall be withdrawn at
the latest by April 2002.
This European Standard has been prepared under a mandate given to CEN by the European Commission
and the European Free Trade Association, and supports essential requirements of EC Directive(s).
For relationship with EC Directive(s), see informative Annex ZA, which is an integral part of this standard.
This standard is Part 1 of a European Standard specifying the safety requirements for hydraulic powered
roof supports.
Other parts are:
Part 2: Power set legs and rams
Part 3: Hydraulic control systems
1
Part 4 ): Electro-hydraulic control systems
Annex A is normative.
This standard includes a Bibliography.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark,
Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal,
Spain, Sweden, Switzerland and the United Kingdom.
0 Introduction
This European Standard is a Type C-standard as stated in EN 1070.
The extent to which hazards are covered is indicated in the scope of the standard.
While producing (or when compiling) this standard it was assumed that:
- only trained and competent persons operate the machine;
- components without specific requirements are:
a) designed in accordance with the usual engineering practice and calculation codes;
b) of sound mechanical construction;
c) free of defects.
- components are kept in good working order;
- a negotiation took place between the user and the manufacturer concerning the use of the machin-
ery.
1 Scope
This standard specifies the safety requirements for support units when used as specified by the
manufacturer or his authorised representative. Examples of support units are frame supports, chock
supports, shield supports, paired frames and push-pull support systems including the components of
advancing and anchoring devices which provide support functions. This part of the standard excludes fixing
elements on the conveyor, coal-winning equipment, power set legs and rams, valves, hydraulic and electro-
hydraulic control units, lighting and signalling facilities and other ancillary equipment.
NOTE Some components are dealt with in other parts of this standard.
This standard applies to support units used at temperatures from -10° C to 60° C.
This standard also applies to support components and support accessories which are provided if the
support unit is fitted with stowing equipment. This standard identifies and takes account of:

1
) in preparation
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EN 1804-1:2001 (E)
- Possible hazards which may be caused by the operation of support units;
- Areas and operating conditions which may create such hazards;
- Hazardous situations which may cause injury or may be damaging to health;
This standard describes methods for the reduction of these hazards.
A list of hazards covered appears in clause 4.
This European standard does not establish the additional requirements for:
- Specially corrosive environments;
- Hazards occurring during construction, transportation, decommissioning;
- Earthquake.
This standard is applicable to all support units placed on the market for the first time, which are
manufactured after the date on which this standard was published.
2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications.
These normative references are cited at the appropriate places in the text, and the publications are listed
hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply
to this European Standard only when incorporated in it by amendment or revision. For undated references
the latest edition of the publication referred to applies (including amendments).
EN 287-1 Approval testing of welders - Fusion welding - Part 1: Steels.
EN 288-1 Specification and approval of welding procedures for metallic materials - Part 1: General
rules for fusion welding.
EN 288-2 Specification and approval of welding procedures for metallic materials - Part 2: Welding
procedure specification for arc welding.
EN 288-3 Specification and approval of welding procedures for metallic materials - Part 3: Welding
procedure tests for the arc welding of steels.
EN 292-1:1991 Safety of machinery - Basic concepts - General principles for design - Part 1: Basic
terminology, methodology.
EN 292-2:1991 Safety of machinery - Basic concepts - General principles for design - Part 2: Technical
+ A1:1995 principles and specification.
EN 1050:1996 Safety of machinery – Principles for risk assessment.
EN 1070 Safety of machinery – Terminology.
EN 1804-2 Machines for underground mines - Safety requirements for hydraulic powered roof sup-
ports - Part 2: Power set legs and rams.
prEN 1804-3 Machines for underground mines - Safety requirements for hydraulic powered roof sup-
ports – Part 3: Hydraulic control systems.
ENV 1993-1-1:1992
Eurocode 2: Design of steel structures - General rules and rules for buildings - General
rules and rules for buildings.
EN 10002-1 Metallic material - Tensile testing - Part 1: Method of test.
EN 10025:1990 + A1:1993 Hot rolled products of non-alloy structural steels - Technical delivery conditions.
EN 10045-1 Metallic materials - Charpy impact test- Part 1: test method.
prEN 13463-1:1999Non-electrical equipment for potentially explosive atmospheres- Part 1: Basic method-
ology and requirements.
EURONORM 103:1971
Microscopic determination of the ferrite or austenitic grain size of steels.
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EN 1804-1:2001 (E)
3 Terms and definitions
For the purposes of this standard the following terms and definitions apply.
3.1
designs of hydraulic powered roof support
3.1.1
support unit
type of hydraulic powered roof support, e.g. frame support, chock support, shield support, consisting of
support components and support accessories
3.1.2
frame support
support unit in which the canopy and the base are connected to legs arranged in a line one behind the other
to form one support unit
3.1.3
chock support
support unit in which the canopy and the base are connected to legs arranged one behind the other and
side by side to form one support unit
3.1.4
shield support
support unit in which the canopy and the base are connected additionally via a goaf shield which lies within
the flow of the support bearing force
3.1.5
paired frame
at least two support units arranged side by side moving lengthwise against each other using an advancing
mechanism
3.1.6
push-pull support
at least two support units arranged one behind the other moving lengthwise against each other using an
advancing mechanism
3.2
support components
all components which lie within the flow of the support bearing force
3.2.1
canopy
single or composite support component which transfers the support bearing force to the roof
3.2.2
base
single or composite support component which transfers the support bearing force to the floor
3.2.3
goaf shield
support component intended to absorb and transfer, fully or partially, the support bearing force and forces
parallel to the seam between canopy and base. It is connected to the canopy and base either directly or
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EN 1804-1:2001 (E)
through a linkage. It generally shields the face area from the waste and is therefore subjected to a load from
the caved material
3.3
support accessories
all components which do not lie within the flow of the support bearing force but which are necessary for the
functioning of the powered roof support
3.3.1
advancing mechanism
device attached to the support unit for moving the support forwards
3.3.2
sprag
device attached to the support unit for supporting the working face
3.3.3
forepoling device
device used to protect the face area from caving materials
3.4
anchoring device
device for preventing uncontrolled movements of the conveying and extracting machines
3.5
forces
3.5.1
yield force
force produced by an actuator at the yield pressure of the pressure limitation valve, neglecting friction
3.5.2
rated force
maximum force for which the support unit or support component is designed. It is a calculated value which
is determined from the support geometry neglecting friction
3.5.3
support bearing force
force borne by a support unit normal to the strata, which is a function of the support height and which
occurs at the yield force
3.5.4
test force
measured force required to be applied to the support unit or support component to ensure that it is
subjected to the rated force
3.5.5
additional force
force acting on the support unit, not produced by the strata or the support components
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EN 1804-1:2001 (E)
4 List of hazards
All the items in the following list of hazards refer to continuous operation and to installation and
maintenance.
This list contains the hazards and hazardous situations, as far as they are dealt with in this European
Standard, identified by risk assessment significant for this type of machinery and which require action to
eliminate or reduce risk.
Table 1 - List of hazards with cross references to safety requirements
No. EN 1050:1996 Safety requirements (clause) Hazards
1 1.1; 1.2; 1.3 5.1.1 Crushing, shearing and cutting
2 1.9 5.1.3 fluid injection
3 17 5.4.1 Ejected parts
4 1e 5.1.6; 5.1.7; 5.3.1; 5.3.2; 5.3.4; Fatigue or overload
5.3.5; 5.3.6; 5.3.7;5.4.1;5.4.3; 5.5;
5.6; 5.7
5 19; 21.1 5.1.1 Slipping, stumbling and falling in the
support
6 2.4 5.4.3 Electrical energy resulting from electro-
static processes
7 7.1 5.1.2 Inhaling harmful dusts
8 7.2 5.4.2 Fire or explosion
9 8.1; 8.2 5.1.1 Neglecting ergonomic principles leading
to unhealthy postures or excessive strain
10 5.1.8 Incorrect assembly
11 18; 30.1 5.2.1; 5.2.2; 5.3.7 Tipping over, unexpected loss of stability
12 5.1.4 Absence or incorrect installation of
safety (protective) devices
13 5.1.5 Absence or incorrect installation or im-
portant devices and auxiliaries for erec-
tion and repair
14 1.C 5.1.5; 5.1.7; 5.1.8; 5.2.1 Potential energy of support unit parts
which may move under the effect of
gravity
5 Safety requirements
5.1 General requirements
Hydraulic powered roof supports, which are designed according to this part of EN 1804, shall also meet the
requirements of the other parts of EN 1804.
Support units should comply as appropriate with EN 292-1:1991 and EN 292-2:1991 + A1:1995 for hazards
which are not covered by this standard.
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EN 1804-1:2001 (E)
5.1.1 Access
The travel-way through the support unit shall have minimum dimensions of 0,6 m in width and 0,4 m in
height with corner profiles of minimum dimensions as given in Figure 1.
The walkways shall be designed to minimise slipping hazards e.g. by the use of ribbed plates.
Dimensions in millimeters
Figure 1 - Minimum travel way
5.1.2 Protection against dust
Provision shall be made in the design of support units for the installation of dust suppression equipment.
That needs to be in accordance with the user’s requirements (see clause 0, last indent).
NOTE Support units should be designed to seal the travel way from ingress of dust from the roof and goaf as far as
possible.
5.1.3 Protection against ejected fluids
Support units shall be so designed that no hydraulic elements are damaged when used as intended.
5.1.4 Protection against face material spalling
Support units having a maximum extended height of 2,5 m or more shall be fitted with devices to which
sprags can be attached.
The sprags shall be positively lockable when in the retracted position.
5.1.5 Lifting and pulling points
Support units shall have lifting and pulling points.
Lifting and pulling points shall be suitable for their intended purpose. They shall be designed to have a
calculated minimum factor of safety of 4 on ultimate breaking load in relation to their intended load carrying
capacity. They shall be clearly and permanently marked with their load carrying capacity, e.g. by welding.
5.1.6 Forepoling devices
Forepoling devices shall not lead to damage to other parts of the support unit when loaded with the rated
force.
5.1.7 Prop anchorages
Canopies of hydraulic powered roof supports shall be equipped with anchorages for the top plates of the
individual hydraulic props.
5.1.8 Correct assembly
It shall be possible to assemble the support unit correctly in accordance with the assembly instructions
provided by the manufacturer.
5.2 Stability and alignment requirements
5.2.1 Tilt-resistance
When handled in accordance with the manufacturer's instructions support units in a freestanding state shall
be stable over their whole adjustment range on all sides on a gradient of up to 15°.
In addition, they shall be stable in operation e.g. with external stabilising means.
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EN 1804-1:2001 (E)
5.2.2 Alignment
With support units for use in inclined seams with gradients of more than 30°, the alignment force (push or
pull) of a support unit which is set shall be greater than the lateral weight component of three adjacent
support units which are not set if these support units are no longer stable in the free-standing state.
5.3 Design requirements
5.3.1 Yield capability
Support units shall be designed for yielding to absorb convergence between the roof and the floor. During
convergence the rated force shall not be exceeded by more than 20 %.
NOTE Support units should be designed in such a way that their function is impaired as little as possible by caved
waste when lowering.
5.3.2 Behaviour when overloaded
Support components including face sprags shall be designed so that no failure occurs by bending, tension
and compression when they are loaded up to 1,2 times the yield force of their respective actuators.
5.3.3 Eccentric loading
Support units shall be designed in such a way that their ability to function is not impaired in the presence of
eccentric loading e.g. if the canopy is in contact with the roof on one side only.
5.3.4 Loading resulting from caving or stowing
Support units shall be capable of withstanding the caving or stowing forces resulting from over tipping when
operated on a gradient when working an over tipped face. The forces and the gradients to be expected are
normally be provided by the user (see clause 0 last indent).
5.3.5 Horizontal loading
Support units shall be designed to accommodate horizontal loads.
Shield supports shall withstand a horizontal force corresponding to 0,3 times the support bearing force
without any damage to the support components.
All other support units shall either withstand the forces induced by the advancing mechanism or allow
relative movement between canopy and base:
a) towards the waste, of at least 80 mm per metre of supported height and
b) in the coal face direction and to both sides, of at least 40 mm per metre of support height.
5.3.6 Operational performance
The operational performance of the support unit shall remain unimpaired when subjected to a total of at
least 26 000 load cycles with various load configurations (see A.1.3).
5.3.7 Force introduction points of legs and rams
The force introduction points of actuators shall be capable of withstanding 1,5 times the maximum tensile
force and the compression force which can be generated by the support hydraulics without their function
being adversely affected.
5.4 Materials
5.4.1 Steel
5.4.1.1 General
The manufacturer shall specify the steel grades and characteristics to be used.
The tensile strength of the steel grades used shall be at least 1,08 times the measured yield point or 0,2 %
proof stress if the calculated stresses are more than 90 % of the permissible stresses (see 5.5).
The elongation prior to fracture A of the steel grades used shall not be less than 10 %, with the exception of
steel grades used for pins where the elongation shall not be less than 9 %.
For thermal cutting of the steels, the steel manufacturers processing specifications shall be observed.
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EN 1804-1:2001 (E)
5.4.1.2 Steel for welded support components
The steels shall be fully killed and either
a) conform to EN 10025:1990 + A1:1993, De-oxidation type FF or
b)
1) be of grain size 6 or finer as described in EURONORM 103:1971; and
2) shall have the following minimum impact values at a temperature of –20 °C:
20 J for steels with a 0,2 % proof stress of <620 N/mm²
25 J for steels with a 0,2 % proof stress of > 620 N/mm²
The values given shall be obtained regardless of the sample position, transverse or longitudinal to the
direction of rolling.
The steels shall be weld able.
5.4.1.3 Steel for non-welded support components
The steels shall be killed.
The impact values of the steel grades shall be at least 25 J at room temperature (20 °C).
5.4.2 Light metal
Surfaces consisting of light metal or light metal alloys (including paints and coatings containing light metal)
of actuators intended by the manufacturer to be used in potentially gaseous mines shall meet the
requirements of clause 8 of prEN 13463-1:1999.
5.4.3 Other materials
Other materials shall conform to the material specification laid down by the support unit manufacturer.
When such materials are used for the manufacture of support components, equivalent performance
characteristics to those specified for steel in 5.4.1 shall be proven. Non-metallic materials shall meet the
requirements of clause 7 of prEN13463-1:1999.
5.5 Permissible stresses
5.5.1 General
Static load calculations shall be carried out for all support components.
Additional forces which stress a support component shall be taken into account.
The stresses in the support components determined by calculation either shall not exceed the permissible
stresses given in 5.5.2 to 5.5.5 or the manufacturer shall demonstrate by theoretical or experimental
methods that the support component performs in a safe manner.
5.5.2 Calculated axial stresses
For canopies, bases and footplates the calculated axial stresses shall not exceed the guaranteed minimum
yield point or 0,2 % proof stress values of the materials. For other support components, the calculated axial
stresses shall not exceed 85 % of these values.
5.5.3 Calculated shear stresses
The calculated shear stresses shall not exceed 80 % of the calculated axial stresses allowed for each
support unit and load case.
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EN 1804-1:2001 (E)
5.5.4 Calculated combined stresses
The calculated combined stresses shall not exceed the guaranteed minimum yield points or 0,2 % proof
stress of the materials.
5.5.5 Calculated weld stresses
The calculated weld stresses shall not exceed the following values of the permitted stresses of the adjacent
materials. The welded joints and combined stresses shall be calculated in accordance with ENV 1993-1-
1:1992 or an equivalent method.
Table 2 - Weld stresses
Weld type axial stresses Shear stresses Combined stresses
Fillet welds 65 % 65 % 100 %
Butt welds 100 % 65 % 100 %
5.6 Articulated joints
Articulated joints which lie in the flow of the support bearing force shall be designed so that the permissible
stresses as specified in 5.5 are not exceeded when subjected to:
a) central loading at 1,5 times the rated force;
b) horizontal loading at the rated force (see Figure A.6);
c) eccentric and central loading when combined at the rated force (see Figures A.1, A.2 and A.5).
5.7 Welding
All welding shall be carried out in accordance with EN 288-1, EN 288-2 and EN 288-3. The manufacturer
shall make use of competent welding shops and welders. This can be reached by either:
a) operating a certified quality system according to EN ISO 9001; or
b) a certificate issued by an accredited body confirming compliance with EN 729-3.
The welding shall be done by competent welders approved in accordance with EN 287-1.
6 Verification of the safety requirements
6.1 Type testing
One specimen of the support unit shall be type tested in accordance with Annex A. The test requirements
given in Annex A shall be met. The following documents shall be made available to the laboratory running
the type test:
- User information;
- Results of a static calculation in accordance with A.8;
- Manufacturing drawings;
- Welding drawings;
- Data relating to the material characteristics;
- Evidence of the competence of the welding workshop.
NOTE The specimen which has been tested according to Annex A should not be placed on the market.
If no provision has been made in Annex A for verification of the requirements in clause 5 by specified tests,
they shall be verified by means of visual inspection, function test or reference to documents.
Verification of the safety requirements is shown in Table 3.
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EN 1804-1:2001 (E)
Table 3 - Tests for verification of the safety requirements
Safety requirements Verification
5.1.1 *Measurements
5.1.2 *Visual inspection/comparison with the manufacturers drawing
5.1.3 *See A.6
5.1.4 *Visual inspection/comparison with the manufacturers drawing
5.1.5 *See A.4
5.1.6 *See A.5
5.1.7 *Visual inspection of manufacturer’s test documentation
5.1.8 *Visual inspection/comparison with the manufacturers assembly drawings
5.2.1 *Function tests or calculation
5.2.2 *See A.3
5.3.1 *See A.1.1 and A.1.2.4
5.3.2 *See A.1.1, A.1.2.1 and A.1.2.2
5.3.3 *See A.1.1 and A.1.3.4
5.3.4 *See A.2
5.3.5 *See A.1.1, A.1.2.5 and A.1.3.5
5.3.6 *See A.1.1 and A.1.3
5.3.7 *See A.1.1 and A.1.2.3
5.4.1 **See A.7
5.4.2 **Visual inspection of manufacturers material specification and see A.7.1
5.4.3 **Visual inspection of manufacturers material specification and see A.7.1
5.5 *See A.8
5.6 *See A.8
5.7 **Visual inspection of accredited body certificate
*type test; **series test
6.2 Series verification
See Table 3, clauses signed with **
7 User information
7.1 General requirements
The hydraulic powered roof support manufacturer shall provide user information meeting the requirements
of clause 5 of EN 292-2:1991 + A1:1995 and clause 7.
The user information shall be the primary source of information on a complete hydraulic powered roof
support and shall contain all the information relating to its safe application and this shall be produced as an
instruction handbook as specified in 5.5 of EN 292-2:1991 + A1:1995.
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EN 1804-1:2001 (E)
Care shall be taken to ensure that the user information is available to the user on receipt of the hydraulic
powered roof support. The content and structure of the user information shall comply with 5.1.3 of EN 292-
2:1991 + A1:1995.
7.2 Technical and application data
7.2.1 Introduction
The user information shall describe the intended use of the hydraulic powered roof support.
The operating instruction shall include all design and performance data necessary for the user to make an
assessment of suitability for use in particular applications and environments, and for the identification of any
energy supply requirements and other ancillary facilities that may be needed. The information provided shall
comply with 7.2.2 to 7.2.4.
7.2.2 General description
This description shall explain in clear, easily understandable language of the user and in logical sequence
the overall function of the hydraulic powered roof support with all special features, characteristics and
markings. General arrangement drawings and function block diagrams shall be provided as appropriate.
7.2.3 Performance data
The principal dimensions, weights, centres of gravity and performance capabilities of the complete support
unit and, where applicable, of its main component parts shall be given.
In particular, information shall be provided on:
a) performance capability (e.g. support bearing force and height adjustment range);
b) working conditions and limitations (e.g. by giving details of minimum and maximum effective seam
thickness, minimum and maximum seam pitch in the direction of and at right angles to the advancing
mechanism, minimum and maximum over tip angle of the working and stowing face in relation to
natural seam pitch, measured at the seam level). It shall also be stated for which working method the
support units are to be used, e.g. long wall method with caving, short wall method using pneumatic
solid stowing etc.;
c) operating and control methods (e.g. immediate forward support system, conventional support ad-
vance system, adjacent control and sequential control);
d) hazards and corresponding safety precau
...